BERG KOMPBERG ZX55 Operating instructions

OPERATING AND MAINTENANCE MANUAL
Oil-free screw compressor
KOMPBERG ZX55

Ladies and Gentlemen,
We heartily welcome you among our valued Customers and thank you for your trust to
purchase the BERG compressor.
We are sure you will be fully satisfied with both the choice you have made and the
cooperation you started with us. Our compressors are machines of top quality, which is the
guarantee for a long years and reliable performance.
Our sales and service staff is available to answer all your queries regarding the installation
and operation of your compressor. You are also encouraged to use our warranty and post-
warranty technical service.

Table of contents
1. Information concerning the document...............................................................................4
1.1. Scope and intended use of the manual........................................................................................4
1.2. Intended use of the compressor and conditions of safe use .......................................................4
1.3. Qualification requirements for operation of the compressor......................................................5
1.4. Operation......................................................................................................................................5
1.5. Other remarks and instructions....................................................................................................6
1.6. Warranty.......................................................................................................................................6
2. Operating safety rules .........................................................................................................6
2.1. Basic requirements for safe transport and positioning of the screw compressor.......................7
2.2. Operating safety requirements ....................................................................................................8
2.3. Other hazards...............................................................................................................................8
2.4. Meaning of pictograms.................................................................................................................9
3. Technical data..................................................................................................................................9
4. Setting................................................................................................................................10
4.1. Room requirements................................................................................................................... 10
4.2. Requirements concerning electrical system.............................................................................. 11
4.3. Compressed air connection....................................................................................................... 11
5. Screw compressor operating description..........................................................................12
5.1. Screw compressor KOMPBERG ZX55 –operating description.................................................. 12
Technological diagram...................................................................................................................... 14
6. Start-up..............................................................................................................................17
6.1. Start-up preparation.................................................................................................................. 17
6.2. Restart (after longer downtime)................................................................................................ 18
7. Maintenance......................................................................................................................19
7.1 General requirements ................................................................................................................ 19
7.2. Maintenance and checks........................................................................................................... 20
7.2.1 Maintenance at the beginning of compressor use, after oil and drive belts (if present)
change.......................................................................................................................................... 20
7.2.2 Daily maintenance .............................................................................................................. 20
7.2.3 Periodic maintenance......................................................................................................... 20
7.2.4 Warranty and post-warranty checks .................................................................................. 20
7.3. Basic components requiring maintenance. Maintenance operations................................. 21
7.3.1. Air filter cartridge.............................................................................................................. 21
7.3.2 Cleaning or replacing the filter mats. ................................................................................. 21
7.3.3. Oil filter .............................................................................................................................. 22
7.3.4. Oil level .............................................................................................................................. 22
7.3.5 Changing oil ........................................................................................................................ 23
7.3.6. Handling wastes produced while operating the compressor............................................ 24
7.3.7 Oil cooler (exchanger) / interstage / final air ..................................................................... 24
7.3.8. . Electric motor................................................................................................................... 25
7.3.9 Safety valve......................................................................................................................... 25
8. Troubleshooting.................................................................................................................27
9. Consumables for one year guarantee ...............................................................................30
10. Electrical scheme.............................................................................................................30

1. Information concerning the document
This operating and maintenance manual is an integral part of the machine. It includes the
information necessary to start, operate and maintain the compressor and requirements for its
safe operation.
Following the manual rules will help you:
▪Avoid hazards,
▪Reduce repair costs and downtime,
▪Increase the machine reliability and life.
Getting familiar with this manual in detail, using the machine in accordance with descriptions
included in it and following all safety conditions are the basis for correct and safe operation of
the machine.
In addition to the operating and maintenance manual and the regulations applied in the country
of destination and health and safety at work regulations applied locally at the workstation, the
generally recognised technical rules for safe and correct work are also valid.
1.1. Scope and intended use of the manual
The operating and maintenance manual is intended for qualified / suitably trained operating
personnel of the compressor. The personnel assigned to operation of the compressor must,
before starting work, get familiar with the manual contents, in particular the “Health and safety
at work regulations” section.
The manual includes
▪Description of daily service and maintenance of the compressor and control system,
▪Technical documentation of the electrical part. It includes the data necessary to perform correct
connections and repairs of the electrical equipment,
▪Technical documentation of the mechanical part. It includes the data necessary to perform repairs
of the mechanical equipment,
▪Technical documentation of the control system. It includes the data necessary to switch on and
off, and set operating parameters of the compressor.
The qualified personnel is understood to be the persons who because of received training,
experience and knowledge of important standards, documentation and regulations concerning
safety and operating conditions were authorised to carry out necessary operations and are able
to recognise and avoid possible hazards.
1.2. Intended use of the compressor and conditions of safe use
The compressor is designed to produce only compressed air. It should be installed in accordance
with the stipulations concerning the compressor installation and connection. The compressor
must not be used for any other purposes that are non-compliant with its intended use. The
manufacturer shall not be liable for any damage resulting from that reason. In that case, the risk
is born by the machine user only.
During the compressor operation, you must follow the procedures given in the “Maintenance”
section as regards scope and frequency of maintenance work and materials to be used.

Warning bout forbidden use
▪The compressor must not be used for any other purposes that are non-compliant with its
intended use.
▪Under no circumstances must the limit operating parameters of the compressor be exceeded and
changed - refer to section 10 "Technical data".
▪To use it for compression of other gases than air, it is required to obtain the manufacturer’s
consent. The above consent must be in written form.
▪The compressor must not be used in potentially explosive atmospheres within the meaning of
Directive 2014/34/UE.
▪The compressor must not suck any toxic, acid-containing, flammable or explosive gases and
vapours.
▪Never direct a jet of compressed air at people or animals.
Safe use of the compressor
▪The compressor must be operated in accordance with all guidelines included in this operating
and maintenance manual.
▪The sucked air must be clean and must not contain any harmful substances.
▪The heated cooling air may be used for heating purposes if only its harmfulness to people and
animals is excluded. Otherwise, it is necessary to provide the appropriate treatment of cooling
air.
▪Compressed air may only be used for breathing after its appropriate treatment.
▪Compressed air not subjected to the appropriate treatment must not be used in production
processes in which there is contact of air with food.
The compressor delivered is designed to compress only air.To use it for compression of other
gases, it is required to obtain the manufacturer’s consent. The above consent must be in written
form. The compressor must not be used for any other purposes that are non-compliant with its
intended use.
Fulfil the obligation to register the compressor air receiver in the Office of Technical Inspection
(UDT).The compressor documentation is accompanied by the set of the required documentation
of the air receiver (if applicable) and safety valve.
1.3. Qualification requirements for operation of the compressor.
The personnel who installs, operates and maintains the compressor should have the appropriate
education and qualifications enabling safe operation of electro technical and electrical
equipment.
Installation, operation and maintenance of the compressor may only be carried out by the
persons who are familiar with this operating and maintenance manual, follow instructions
included in it, know safety regulations and recognised technical rules.
1.4. Operation
While operating the compressor:
-Observe the instructions provided in the Operating and Maintenance Manual and Warranty Book.
-Follow the periodic inspection schedule during both warranty period and after its completion.
Regular performance of periodic inspections is necessary to ensure the required reliability and life
of the BERG equipment. The inspections performed according the schedule reduce the number of
repairs and their cost.
-The technical and operating inspections should be carried out in accordance with the schedule
and conditions by the factory service or authorised service, using the manufacturer’s consumables
and spare parts.

-During the warranty period, use only the manufacturer’s consumables and spare parts.
The detailed list of maintenance operations can be found in the "Maintenance and inspections"
section.
1.5. Other remarks and instructions
-This Operating and Maintenance Manual provides all information on how to install, start and
operate the compressor. This manual should also be used when any maintenance work is carried
out,
-The Manual should be read and always available to the compressor operator,
-During the maintenance work and periodic inspections, the provisions of the Warranty Book
should be observed,
-The Maintenance section provides all measures and requirements necessary to keep the
compressor in a correct technical state,
-Record all operating data, maintenance operations performed etc. into the Warranty Book.
Observe all reference and local safety regulations relating to the compressor, including those
listed herein and in the following sections,
-Failure to follow the requirements included in this Operating and Maintenance Manual and
Warranty Book and/or unauthorised changes in the compressor or its integral units delivered by
us shall make the warranty null and void.
-During warranty period, any repairs must be performed by the manufacturer service or
authorised service centre listed in the Warranty Book.
1.6. Warranty
BERG Kompressoren GmbH. Speddition Straße 21, 40221 Düsseldorf Germany
hereinafter referred to as the Warrantor provides the warranty for the products sold, ensures
correct operation of the offered products provided that they are used in accordance with their
intended use and operating conditions specified in this documentation.
The Purchaser shall lose its warranty rights for the product when:
-The machine is used in a way non-compliant with its intended use,
-Unauthorised modifications are carried out on the product,
-Interventions are carried out by unauthorised persons,
-Any repair attempts are carried out by unauthorised persons,
-The obligation to carry out periodic inspections is not observed,
-Non-original consumables are used.
The manufacturer reserves the right to make modifications in the product, resulting
from continuous technical development, without prior notice.
2. Operating safety rules
The present rules are valid for BERG screw compressors. In addition to the general health and
safety at work and the Office of Technical Inspection (UDT) regulations applicable to
compressors, their assemblies and accessories, the safety instructions given below should be
followed in particular. The operators are supposed to observe safe work practices. It is the user’s
responsibility to continuously maintain the compressor fully operable. Components and
equipment considered to be no longer suitable for safe operation should be promptly replaced.
Adjustments, installation, operation, maintenance and servicing should be entrusted only
to properly trained, qualified and authorized staff.
The limit values (pressure, temperature, time settings etc.) are given in the Technical Data
section.

The limit values may not be changed by the user.
The manufacturer accepts no responsibility for any personal injuries, damage of equipment or
the compressor itself, at present and in the future, resulting from user’s negligence and failure to
observe the installation, operation and maintenance requirements contained herein. No
responsibility is also taken for failure to observe valid safety standards relating to the equipment
and qualified staff.
2.1. Basic requirements for safe transport and positioning of the screw compressor
In addition to the general health and safety at work and the Office of Technical Inspection (UDT)
regulations, the following rules must be observed:
-Use only the lifting equipment that is compliant with the H&S and UDT regulations to lift the
compressor. Fix in place all rotating or loose parts of the machine before its lifting. It is strictly
forbidden to stay in the hazardous zone of the lifting equipment operation. The compressor
movement can be accelerated or slowed down only within the permissible limits.
-When the compressor is transported, the transport straps should be pulled under the machine
and secured above the housing in such a way that they do not place pressure on it. If the
transport harness is fastened and secured incorrectly, the machine may get damaged.
-The compressor must be transported only with a forklift.
-Fasten the compressor frame with cargo straps to appropriate holders on the vehicle platform to
prevent it from sliding or overturning.
-All screw and pipe connections should be of appropriate size and designed for a given operating
pressure.
-The compressor is not designed to operate outdoors; it cannot be exposed to weather
conditions.
-The compressor should be positioned in a closed room, where ambient air is cool and clean.
Never block air flow to and from the room. Ensure sufficient inflow of cooling air and discharge of
hot air outside the room. Temperature in a room with the compressor should be within the
rangeof + 5C to + 40C.
-The air sucked in should contain no vapours or flammable gases, e.g. paint thinners, that might
cause internal fire.
-There can be no objects close to the air inlet that could be sucked in with a jet of air.
-The pressure conduit connecting the compressor with the compressed air line should allow free
expansion due to generated heat. It must not touch hot objects or flammable materials.
The detailed requirements concerning the machine positioning in the compressor room are
described in section 4.1.
Transport of the machine with a forklift.

2.2. Operating safety requirements
In addition to the requirements contained in the sections: Screw compressor operation
description; Start up; Maintenance; the following rules should be observed.
-The compressor is only designed to compress air.
-All safety equipment must be in place while operating the machine.
-The factory-mounted safety equipment must not be removed. Please, remember to remove any
transport brackets (if applicable)before first start-up of the compressor. The transport brackets
are only used to protect the machine during transport.
-There are hot parts in the compressor e.g. conduits, air and oil coolers, screw block. They will
scald when touched.
-No unauthorized modifications in the control system are allowed. After power failure,
the compressor must be restarted when the power supply is recovered.
-It is prohibited to remove the green and yellow protective conductors that prevent electric shock.
-No additional equipment can be mounted on the air receiver(except for the equipment allowed
for use by the manufacturer).
-No welding operations or any other repairs can be performed on the air receiver.
-The plugs and other air receiver accessories can only be removed after the air receiver
depressurisation to the ambient pressure.
-General safety rules should be observed while depressurising the air receiver. Air must be vented
slowly. Keep the air stream away from people.
-Do not allow oil spill around the compressor.
-It is strictly prohibited to service the safety valves or to change their settings.
-Do not change settings of the pressure switches above the value given in the identification plate
or in the Operating and Maintenance Manual.
-Fulfil the obligation to register the compressor air receiver in the Office of Technical Inspection
(UDT). Two sets of the required documents of the air tank (if provided) and safety valve are
included with the compressor documentation. The compressor documentation is accompanied
by the set of the required documentation of the air receiver (if applicable) and safety valve.
-Do not remove the temperature sensor (transmitter) or pressure transmitter.
2.3. Other hazards
The compressor installation, switching on/off and maintenance must be carried out by the
qualified personnel who strictly follows the data included in the product technical documentation
and safety rules to avoid any hazards. The risks that could not have been eliminated during the
design stage are described in the table below.
Unit
Residual risk
Action
Precautions
water cooler, frame
minor cuts
touching
avoid touching, wear
protective gloves
screw assembly, end
cooler, pressure
conduits
danger of
scalds
touching
avoid touching, wear
protective gloves
metallic parts and
electric wire
electric shock
damage of wire
insulation upstream
the motor breaker,
live metallic parts
adequate guard for the
power supply lead; check
the wire insulation for
damages
around the
compressor
danger of scalds
fire due to shorting
or overheating of the
power cord before
the electrical box
use the cross section of the
power cord and the
protection corresponding to
the applicable standards

2.4. Meaning of pictograms
Pictograms (safety symbols) located on and inside the compressor are described below.
Explanation is provided below any of them.
For technical reasons, it is not always possible to attach the pictograms in the very vicinity of the
points of risk.
3. Technical data
*) - Capacity measured acc. to EN ISO 1217: 2006 and EN ISO 5167-2.
**) - Noise level acc. to EN ISO 2151.
- Momentary value of acoustic pressure corrected by C characteristic does not exceed 130dB.
- Equivalent acoustic pressure level corrected by A characteristic does not exceed 85 db(A).
AUTOMATIC MACHINERY
MAY START
RISK OF SCALDING
RISK OF ELECTRIC SHOCK
Type
KOMPBERG ZX55
Overpressure*
MPa
1,0
Max capacity
m3/h
397
6,61
m3/min
Weight
kg
3400 kg
Dimensions (LxWxH)
mm
2500/1400/2000
Compressed air connection
G 1 1/2
Ambient temperature
0C
+5 ÷ +40 0C
Compressed air temperature
0C
+10 do 15 0C above ambient
temperature
Noiselevel L**
DB(A)
85
Screw air-end type
CD8D
Nominal motor power
kW
55
Supply voltage
400V/50Hz/3ph
Nominal fan motor power
kW
4
Cooling air requirement
m3/h
16500
Power lead cross sectional area
mm2
3x50+PE
Protection
A
125

4. Setting
4.1. Room requirements
-The compressor requires no foundations. It must be positioned on a hard and even surface. Take
into consideration the floor load capacity, if the machine is installed in a building.
-Strictly observe the minimum distances from walls and other machines. When several
compressors are installed, pay attention to the direction of cooling air flow; no compressor
should suck air which is heated by other machine. Minimum distances from the room walls and
other objects are given in the drawings below.
-Protect the room in which the compressor is installed from negative temperatures. The inlets and
outlets to and from the room should be located in such a manner to protect the interior from
weather conditions.
-Heat generated during compression should be extracted outside (or to other rooms), and fresh
air should be supplied from the outside.
-If the gravity ventilation is insufficient (windows, openings in a wall etc.) in the compressor room,
air exchange should be provided by fans. To ensure correct heat extraction, the fans should have
total capacity about 15 to 20% higher than the total cooling air requirement for all compressors
installed in the room. The required cooling air volume is specified in the Technical Data section.
-Ambient temperature in the room should be from + 5C to +40C.
-Provide sufficient room for maintenance operations.
-It is necessary to consult our specialists when you want to install a duct supplying air from
the outside or use air for heating the rooms.
-The compressor room should be well lighted to ensure trouble-free and safe service of the
equipment.
-To improve ventilation in the compressor room, the machine can be connected to the discharge
air duct; in such case, please contact BERG.
The suitable ventilation in a room will prevent the possibility of negative pressure generation or
undesired temperature increase.
When there are any problems in ensuring the suitable ventilation in a room, please contact BERG.

4.2. Requirements concerning electrical system
-The compressors are designed to be supplied by a four-conductor 400 V AC, 50 Hz power line.
-The compressors are equipped with PE terminal.
No.
Compressor type
Power lead cross
sectional area
mm2
Fuse size
NH gL/gG, 500V, 100kA
D gL/gG, 500V, 50kA
1
KOMPBERG ZX55
3x50mm2+PE
125
-The power cable cross sectional area should be matched to the current drawn by the
compressor.
-The compressors can only be operated on three-phase earthed system (TN).
-The compressor must be supplied from the distribution board equipped with a slow blow fuse
and circuit-breaker that enables the compressor power supply to be completely disconnected.
-Electrical connection of the compressor should be performed in accordance with the attached
electrical diagram.
-Only authorised personnel or qualified electrician is allowed to perform electrical connections.
-Use the required safety measures in accordance with the suitable regulations.
-Calculate the power cable cross sectional area and fuse sizes according to the local regulations
and operating conditions.
-Below there are presented the recommended power cable cross sectional areas and fuse sizes
for standard compressors.
-A user takes a full responsibility for selection of an electrical system and power supply connection
for the compressor.
Recommended power cable cross sectional area and fuse sizes
4.3. Compressed air connection
It is recommended to use galvanized steel or plastic tubes for the compressed air
system.
When the compressed air treatment equipment (filters, dryer) is installed, the existing
compressed air piping should be replaced with a new one, unless air supplied
previously was treated by similar equipment.
Each BERG compressor should be connected to the compressed air network by using a
flexible conduit or flexible connector (axial expansion joint) and shut-off valve.
Compressed air
outlet
Pneumatic
hose
Elbow

5. Screw compressor operating description
5.1. Screw compressor KOMPBERG ZX55 –operating description
General view of an oil-free screw compressor KOMPBERG ZX55

The compressor is equipped with two stage air end ("of dry-type") without oil injection into the
compression chamber with the bearings and gearing and the coat of the high pressure part are
lubricated and cooled with oil.
POWER AND CONTROL
The compressor (screw air-end) is driven by an electric motor through a flexible coupling . Control
of the entire electrical system is placed in a electrical box.
AIR CIRCULATION
The air is sucked through the air filter (1) and the suction controller (2) to the first stage (3). The
compressor suction regulator is equipped with a second stage discharge (4) terminated by a noise
damper (5). After compression to the overpressure of 0,35 MPa the air is forced from the 1st
stage to the intercooler (air-water exchanger) (6). After cooling in the cooler, the air flows through
the condensate separator (7) and is sucked to the second stage (8). I-stage compression and
internal system are protected against pressure rise above the permissible value by a safety valve
(9). After compression, it reaches an overpressure of up to 1,0 MPa and is forced into the end
cooler (air-water exchanger) (10), and then through the check valve (11) to the compressor outlet.
OIL CIRCUM
The oil is sucked by the pump (13) from the compressor reservoir (13) and is forced to the
overflow valve (16) in which the oil overpressure is limited to 0.25-0.30 MPa and then flows to
the oil filter assembly (18). The oil filter set is fitted with a thermostat (17) which, depending on
the oil temperature, directs the oil directly through the oil filter (18) to the manifold (19) or at
temperature exceeding 55 ° C to the oil cooler (20) and then through oil filter (18) to the
manifold (19). The pressure in the manifold is limited to 0.14-0.16 MPa with an overflow valve
(15). The outlets from the oil filter assembly to the oil cooler and inlet from the radiator to the
unit are equipped with electromagnetic shut off valves (21) and (30) which are closed (normally
closed NZ) when in the de-energized condition. These valves are designed to prevent the flow of
oil from the radiator to the installation and further to the oil tank, which avoids the need to
always fill the radiator with oil after the compressor's standstill. In addition, the oil level display in
the sight glass (22) is always reliable (without shut off valves the sight glass would be completely
filled with oil).
From the manifold the oil is distributed to both compression stages ie bearings, seals and coats of
I-stage and II- stage. After passing through the compressor, the oil flows to its reservoir (14).
After the filter, the oil is also fed to the three-way valve (23) and, depending on the compressor
load, flows to the hydraulic cylinder (24) controlling the shutter (25) in the suction controller (3).
In the second position, the oil from the valve (23) flows to the compressor reservoir (14). Also the
oil from the hydraulic cylinder is directed to the compressor tank.

Technological diagram
1
Air filter
19
Oil filter
2
Suction valve
20
Overflaw valve
3
First stage
21
Oil distributor
4
Venturi nozzFirst stage coolerle
22
Vent filter
5
First satage cooler
23
Hydraulic cylinder
6
Cyclone separator
24
Solenoid valve
7
2nd stage
25
Solenoid valve with time system
8
Venturi nozzle
26
Air filter pollution sensor
9
2nd stage cooler
27
Temperature sensor
10
Check valve
28
Safety valve
11
2nd stage unloading
29
Pressure sensor
12
Silencer
30
Temperature sensor
13
Oil sight glass
31
Temperature sensor
14
Oil tank
32
Temperature sensor
15
Oil pomp
33
Safety valve
16
Thermostatic valve
34
Pressure sensor
17
Solenoid valve
35
Temperature sensor
18
Oil cooler
36
Pressure sensor
37
Manometer

MEASURING SENSORS
The following temperature sensors and pressure transducer are installed in the compressor
installation:
(39) - air filter pollution sensor,
(33) - temperature sensor - realizes the measurement of the compressed air temperature after
the I stage (3),
(35) - temperature sensor - realizes the measurement of the compressed air temperature after
cooling in the radiator (6),
(34) - pressure transducer - performs measurement of air pressure after the radiator (6),
(38) - temperature sensor - realizes air temperature measurement after the II stage (8),
(37) - temperature sensor - realizes air temperature measurement after the radiator (10),
(36) - pressure transducer - performs the measurement of compressed air pressure after the
cooler, behind the check valve,
(31) - temperature sensor - performs measurement of oil temperature,
(32) - pressure transducer - performs oil pressure measurement.
These sensors and transducers work with the PLC.
WATER CONDENSATE DRAIN
Water in the compressor airsystem means a very high risk of failure, including the screw air end
failure. This is why the water condensate from the air is carefully drained in the compressor. The
condensate from the separator (7) after the intercooler (6) is drained out of the compressor by
float operated mechanical condensate drain (25).
VENTILATION OF THE SCREW AIR-END INSIDE
During operation of the compressor in the spaces in the interior of its bodies, bearing housings
and seals a small overpressure is produced. This is detrimental to the correctness of the
lubrication and sealing processes. Therefore, these spaces must be ventilated. This is
accomplished by means of a flexible hose and an air filter located at the tunnel of the fan; In the
figure it is marked with a symbol (40).
COMPRESSOR COOLING
The compressor is cooled in a forced manner by means of a fan with its own electric drive. The air
is sucked in through the inlets on the front and rear wall of the housing and pushed through a set
of radiators placed on top of the compressor and thrown outside the compressor.
OPERATION OF THE OIL FREE COMPRESSOR
The compressor is started by pressing the START button on the control panel. After the button is
pressed, the compressor drive is activated. The compressor is designed for intermittent run. The
intermittent operation involves air pressurisation until the maximum overpressure set on the
pressure switch is reached.
When this pressure is reached, the compressor switches to idle running (the hydraulic actuator
closes the air supply on the compressor suction side) and then there is a countdown of the time to
stop. If during this time the air pressure decreases, the compressor will start again, and if not, it
will shut down after the countdown. The compressor is restarted when the overpressure in the
piping drops to the minimum value set in the controller.
The compressor can be stopped at any time by pressing the STOP button on the controller panel.
The operation is resumed by pressing the START button.
When the overpressure in the piping on the compressor start exceeds the value set in
the pressure switch, the compressor will start only after the overpressure drops to the minimum
value.

After stopping the compressor with the EMERGENCY STOP (STOP AWARYJNY) button and after
the supply voltage is switched off and on, the compressor can be started by unlatching the
EMERGENCY STOP (STOP AWARYJNY) button and pressing the START button.
The compressor is provided with an additional protective function which prevents machine start
when any of parameters given in Tab.[Technical data] is exceeded.
Screw air end CD8D

Suction regulator
Operating panel
Controller instruction is an integral part of the OMM of compressor KOMPBERG
ZX55
6. Start-up
6.1. Start-up preparation
Each compressor unit is tested in the factory and carefully inspected to ensure proper machine
performance and meeting the specifications declared.
Strictly obey the following rules before starting the machine for the first time:
-Get thoroughly familiar with the compressor Operating and Maintenance Manual and the
Warranty Book.
-Check the power cables for possible damage, short-circuits and electrical breakdowns. Only
authorised / qualified electrician can perform work on electrical equipment and components.
-Make sure the power supply voltage is correct and the required protections are in place; do not
connect the compressor to a power source of different voltage than that specified in the
Operating and Maintenance Manual.
-Connect the phase conductors so that the rotation direction is as indicated on the screw
assemble.
-Check the oil level in the screw block, top it up, if necessary.
-Connect the compressor to the compressed air system with a flexible conduit.
-A compressed air receiver tank is necessary for proper compressor operation (min. 2500l).
-When the compressed air receiver tank is located outside the compressor room, install the
pressure gauge, connected to the tank or pressure conduit supplying the tank, in a visible
location.
-Do not operate the compressor above the maximum operating pressure that is given on the
identification plate. It is not recommended to operate the compressor at the delivery pressure
below 0.5 MPa. Please contact our technicians when it is necessary to set that overpressure.

-Check if all doors/covers are closed.
-Open the valve that shuts off the compressor from compressed air system.
-Check the “EMERGENCY STOP” button position.
-Switch on the compressor power supply.
When the compressor and compressed air system condition is checked, you can proceed with
starting the compressor.
To start the compressor, press the "START" button on the control panel. The compressor motor
starts working and depending on the overpressure in the compressed air system,the machine
switches to the loaded operation mode or, if the overpressure in the compressed air systemis
higher than the minimum start pressure, it switches to the stand-by mode and starts again after
its drop.
Incorrect rotation direction of the screw block rotors for more than 5 seconds will damage
the screw compressor.
Proper direction of screw air end rotation
6.2. Restart (after longer downtime)
Follow the procedure described below to start the compressor which has been out of use or
stored for over 3 months:
Check if there is no water in the screw assemble.
Turn the compressor shaft several times by hand in the rotating direction.
check oil level in the screw assembly body, top it up if necessary,
Perform the trial run of the compressor screw block lasting for at least 15 minutes.
During the trial run, check the machine for correct operation, noise, vibration, oil leaks and
tightness of connections in the compressed air system.
Rotating
direction of
CD8D

7. Maintenance
7.1 General requirements
To ensure proper functioning, the compressor must undergo maintenance procedures. The
following general requirements must be met while performing the maintenance:
-Place the warning sign as shown below in a visible location, while the maintenance work is in
progress:
WARNING
MACHINE UNDER REPAIR
-All maintenance work should be performed by authorised and trained personnel. Contact
the factory service in case of technical problems.
-Before any maintenance work is started on the compressor, disconnect it from power supply and
protect from unauthorized and accidental starting.
-Check if the supply voltage is lacking.
-Any maintenance and repair work can only be carried out when the compressed air system is
completely unloaded i.e. air pressure in the system is reduced to ambient pressure.
-Before restarting the machine, make sure that there is nobody working on the compressor and
there are no people in the vicinity.
-Use appropriate tools for maintenance and repair work.
-Use only original spare parts.
-For cleaning purposes never use flammable or corrosive solvents that could damage the machine
components. Take appropriate safety measures against toxic vapours from cleaning agents.
Biodegradable detergents should be used.
-The workplace must be kept absolutely clean when maintenance work is carried out. Do not
allow any parts to get contaminated. Parts and exposed holes should be covered with a clean
cloth, paper or adhesive tape.
-Upon finishing the maintenance work, make sure no tools or other objects are left on or inside
the compressor.
-Before restarting the machine after maintenance, check operating pressures, temperatures, time
settings, and test the switching and control equipment for proper functioning.
-Protect the motor, air filters, electric components, control equipment etc. from penetration of
moisture.
-Do not perform any welding or any other works generating heat close to the oil system.
-Under no circumstances should the noise absorbing material be removed or relocated.
The manufacturer accepts no responsibility for any damage and personal injuries resulting from
failure to observe the present safety rules or from carelessness during operation, work and
maintenance, even in circumstances not expressly mentioned in this Operating and Maintenance
Manual.
In order to ensure fault-free operation of the compressor, observe the following instructions
relating to periodic inspections and maintenance operations.

7.2. Maintenance and checks
7.2.1 Maintenance at the beginning of compressor use, after oil and drive belts (if present)
change
Maintenance interval
Operation
after 2 work hours
-check oil level in the receiver, top it up if necessary,
after 2 work days
-check oil level in the receiver, top it up if necessary,
after 1 week of work
-check oil level in the receiver, top it up if necessary,
7.2.2 Daily maintenance
-visually inspect the state of pneumatic and oil conduit connections,
-check the air overpressure gauge and temperature indicator for correct readings,
-check the compressor performance for unusual symptoms, such as excessive noise
and vibration,
-check oil level,
7.2.3 Periodic maintenance
Every 1000 work hours:
-check the air filter for contamination and replace if necessary (in case of higher air dustiness,
more frequent cleaning and changing of the filter is recommended),
-check the condition of the elastic coupling,
-clean the air and oil cooler ribs if necessary.
7.2.4 Warranty and post-warranty checks
every 2000 work
hours
or after 1 year
-change the filter mat at the cooling air inlet,
-change the air filter cartridge,
-check electric clamp terminals, fasten if necessary,
-clean the air and oil cooler ribs,
-test the non-return valve for proper functioning,
-check the condition of elastic coupling,
-check the tubing for leaks, mend if any,
-test the pressure switch for proper functioning,
-check the oil temperature indicator,
-check the condition of safety valve,
-check the motor thermal protection setting.
every 8000 work
hours
or after 1 year
In addition to the activities required after 2000 work hours:
-change the filter mat at the cooling air inlet,
-change the air filter cartridge,
-change oil filter,
-change oil,
-inspect the electric system and check it for proper functioning.
During the warranty period, the checks must be performed only by one of the servicing
companies listed in the Warranty Book